Pile construction and apparatus



Feb; 5, 1929. 1,700,949

N. R. OSBORNE FILE CONSTRUCTION AND APPARATUS Filed Aug. 9, 1924 v 3 Sheets-Sheet 1 35.1. 1% L IE. .2-

' LNVENTOR Ne/son Kane/a Osborne BY I f 1 ATTORNEY Feb. 5, 1929. 1,700,949

N. R. OSBORNE PILE CONSTRUCTION AND APPARATUS Filed Aug. 9, 1924 3 Sheets-Sheet 2 INVENTOR Ne/son Randa/l Osborne TORNEY Feb. 5, 1929. 1,700,949

N. R. OSBORNE FILE CONSTRUCTION AND APPARATUS Filed Aug. 9, 1924 3 Sheets-Sheet 5 INVENTOR Nelson fiandal/ Osborne Patented Feb. 5, 1929.

UNITED STATES PArsNT OFFICE.

NELSON RANDALL OSBORNE, OF NEW YORK, N. Y., ASSIGNOR TOTHE FOUNDATION COMPANY, OF NEW YORK, N. Y., CORPORATION OF NEW YORK.

PILE ooivsrnuerion AND APPARATUS.

Application filed August 9, 1924. Serial No. 731,044.

This invention relates to improvements in pile construction and apparatus. More speciiically, the invention relates to improved means for building piles of various sizes in which the building material is concrete or similar foundation supporting material. The invention relates also to improved means for removing the casing employed in construction of the piles.

In my co-pending application, Serial No. 721,997, filed June 24;, 1924, and Serial No. 729,021, filed July 30, 1924, I have shown a method for constructing concrete piles at considerable distances beneath the earths surface in which I utilize a reciprocating spudding drill or bit toexcavate a vertical shaft, simultaneously lowering a supporting casing in the shaft, this process being continued to bed rock or other weight supporting stratum. In the process referred to, the casing, which may be of metal, is left in the earth after the shaft has been sunk and forms a limiting receptacle for the concrete subsequently filled into the casing. In certain instances, I have found it advantageous where possible, to remove the shell or casing sunk into the shaft during the construction of the pile. The important advantage of this step resides in the increased economy of operation, the same shell being employed for a number of piles instead of for the single pile. This brings about accordingly a reduction in construction costs and a decided economy in material as well as other advantages.

Broadly speaking, therefore, the invention consists in a process by which concrete piles may be constructed, using a shell or casing a number of times instead of a single time as in the prior method referred to above and in providing mechanism by which the shell may be easily inserted and removed and in other improved devices for carrying out the process. The invention relates also to an improved type of pile construction.

In accordance with the general object of the invention above stated, one of the important objects of the invention is therefore a provision of an improved type of apparatus for constructing concrete piles in which the concrete receiving casing is removable after insertion of the concrete. An object of the invention also is the provision of means for forcing the concrete employed in the construction of the piles into the spaces leftby the removalof circumferential casing during the building up of the pile. Another important object is the utilization of an improvedtype of coupling adapted to hold the various sections of easing employed in the construction of concrete piles together without the spread ing and splitting of the ends of the casing.

An object also is contemplated in the provision of an improved type of concrete piling having vertical and unsupported walls. Another object is considered in the employment of a type of casing which permits easy removal after the same has been positioned in the shaft prior to the application of concrete or other foundation supporting material.

Further objects involved in the various steps of the process and apparent from the specific type of mechanism employed which may be preferred in carrying out the process will become evident onconsideration of the detailed description hereinafter made and of the accompanying drawings, in which:

Fig. 1 is a sectional elevation showing the casing of the pile unit in position and a portion of the same filled with concrete;

Fig. 2 is a view of a casing removing mechanism, showing the inner casing partly ex.- tracted from the shaft;

Fig. 3 is a view of another step in the pile construction, showing the inner casing removed;

Fig. 4: is a view of the completed pile with the casing removed;

Fig. 5 is a detail, showing the type of coupling used between the pile casing sections;

Fig. 6 is a view of a clamp employed in the casing removing operation;

Fig. 7 is view, showing the pile casing in relation to the power operating unit;

Fig. 8 is a view of the pile driving mechanism and Fig. 9 is a view of a spuddingbit employed in the drilling of the shaft.

In the process of building a pile according to my present method, I sink a shaft in the earths surface by means of a spudding bit 10, operated by suitable power means 11, as shown for example in Fig. 7, and which may include a gas engine 12, operatively connected by appropriate cables 13 over the derrick supportlt. A suitable reciprocating means causes the bit to dig into the soil and tear away the same in the line of its movement and the loosened soil is removed by water flow or any other appropriate means. Simultaneously or subsequently with the lowering of the shaft by the tool 10, the outer casing 6 is lowered into the shaft. The outer casing may be of variable length but it is preferably a cylindrical metal section of approximately 10 feet in length and the same is lowered by its own weight or through the employment of the ram 16, as illustrated in Fig. 8. This ram is of the type shown in my previously filed application, above referred to,

' and in one form consists of a weighted mass 17, having a depending guide element 18 movable within the casing, the whole being supported from the cable 19 and adapted to be reciprocated against an end flange 20 removably fixed to the upper end of the casing.

Continuing the extension of the shaft, when a depth of approximately 20 feet below the base of the first section has been reached, a second casing section having a length of ap proximately feet, in accordance with the example, is lowered into the shaft, the outer diameter of the second section being such as to permit the casing to telescope within the first section. Subsequently, the shaft is lowcred another unit of approximately 20 feet and a third casing section of approximately 50 feet in length lowered into the second casing and bottom shaft unit.

This alternating operation of shaft excavation and easing insertion may be repeated until the desired depth of casing has been reached or until bed rock has been arrived at, but for purposes of illustrating the process more definitely, it may be assumed that a pile utilizing four sections of easing, as illustrated for example in Fig. 7 is used. Referring to Figs. 1 and 7 it may be assumed that the inner casing rests on bed rock 25. The builder, having cleaned the casing from silt or other foreign matter, fills the inner casing with concrete or similar foundation supporting material from the base stratum to the point adjacent the base of the next outer section, as indicated at 26 in Fig. 1. Preferably, before the concrete is set or simultaneously with the filling in of the concrete, the inner casing is lifted out of the shaft. Fig. 2 showing the shaft in the process of being lifted from its original position.

The mechanism for removing the inn-er casing 9 is shown in Figs. 2 an d 7 and includes a ram unit 27 operated by a power mechanism 11 to force the casing upwardl by a succession of hammer blows on a member attached to the casing. This means consists of a coupling 28, having at its upper end a collar 29 rigidly attached to its exterior by any suitable means. Beneath the collar 29 is a removable clamp 30 formed of sect-ions 31 and 32, as shown in Fig. 6 and held together by bolts 33. As brought out clearly in Fig. 2

the outer diameter of the clamp 30 is greater than that of the collar 29 to an appreciable extent, the purpose of which will be hereinafter apparent.

The base of the coupling 28 carries a plurality of outwardly projecting pins 34;, having heads 35 formed thereon, said pins being adapted to engage right-angled bayonet slots 36, formed in the edge of the second coupling unit 37, as clearly shown in Fig. 2. The coupling unit 37 consists of two circumferential sections 38 and 39, the section 38 being adapted to slide over the coupling 28 and detachably engage the pins 34 in said coupling, and the section 39 having a diameter of such a value as to permit insertion of the coupling inside the casing 9. Connection between the coupling section 39 and the upper casing 9 is made by bayonet slots, including pins 40 fixed to the section 39 and slots 11 formed in the casing. In order to permit application of a unit to casings of varying diameter, it of course, necessary that a plurality of coupling units 37 be employed, the diameters of the section 39 of which vary in accordance with the diameter of the casings.

The ram mechanism employed includes a circular Weighted member 42 slidable upon the coupling 28 beneath the clamp 30. The

inner diameter of the ram member is greater than the external diameter of the collar 29 so as to permit removal of the ram from the coupling 28 over the collar 29 when found desirable especially in such cases where the coupling 28 is permanently attached to the member 37 as may be desirable in some constructions. The cable 43 is fixed at its ends to opposite sides of the ram 42, as indicated at 44. and 45, thus forming a loop engaging the ring support 46 suspended from the operating cable a7, as shown in Fig. 7 of the drawing. It is apparent that by means of the power mechanism specified and by actuation of the pivotally mounted pulley 4L8 a hammer action is obtained, the ram 27 impacting against the clamp 30 and thereby forcing the casing upwardly.

Fig. 2 shows the inner casing displaced upwardly to a point indicated at 50. Note should be made of the fact that as the casing 9 moves upwardly, the space between the wall of the shaft and the concrete remains open until closed either by the settling of the concrete from its own weight or by other means. Ordinarily, I have found it desirable to employ force in moving the concrete into this open space and such means are illustrated in Figs. 2, 3 and 7 of the drawing. Referring specifically to Fig. 7, I have shown a weighted tamp 51 which is approximately 3,000 lbs. in weight although the exact weight may vary with the size of the pile being constructed and with other variable factors involved. The tamp 51 takes the form of an elongated metal mass 52, varying in length from 10 to 20 feet and terminating at its base in an enlarged head 53 having a flat bottom and an annular curved edge.

The diameter of the head 53 is preferably somewhat less than that of the diameter of the casing 9 in which it is adapted to reciprocate. To the top of the tamp is fixed a cabled bail or loop 54, to which is fixed, by means of a connecting ring 55, the supporting cable 56, the latter extending over the derrick pulley 57 and engaging drum mechanism in the power unit. Operation of the tamp is accomplished by reciprocation brought about either by lateral filling pressure against the cable or by means of alternate gripping and slipping of the cable on a nigger head drum according to well known methods of operation. By means of the tamping operation of the tamp 51, the concrete or other foundation material is forcibly moved so as to fill up all interstices and hollow spaces and form a solid mass of the concrete at the base of the casing.

Subsequently to the filling in of the concrete unit 60, the casing 9 is removed, the coupling member 37 changed for a similar member of larger diameter fitting into the next outer casing 8. Concrete is then filled into the casing 8 to the point 61 adjacent the base of the casing 7, forminga second concrete unit 62 and the casing 8 then removed coincident with the second tamping operation. This alternate filling of concrete and removal of casing is repeated, the casings 7 and 6 forming additional concrete sections 63 and 64:, until the pile is completed, the same forming a vertical unit of concrete filling completely the shaft sunk by the spudding tool, the walls of the various concrete sections being slightly stepped as shown at 65 in Fig. 4.

In Figs. 1 and 5, a novel type of coupler is shown adapted to be used in connecting sections of casing. This coupler takes the form of a cylindrical shell 71, having a middle annular external rib 72, the radial thickness of which is approximately that of the casing to which the coupler is applied. Near each end of the coupler are a plurality of pins 73 having fiat heads 74, said pins being adapted to engage the right-angled slots 7 5 formed in the ends of the casing, as shown in Fig. 1. When inserted, the rib 7 2 of the coupler engages at its top and bottom the sections 76 of the adjacent casings and the pins 7 3 engage the corresponding ends of the casings, thus forming a rigid connection between the casing ends and which at the same time is easily separable.

The outstanding advantage of the invention, as hereinabove described, resides in the fact that the casing of the pile is removable. This permits the use of the same casing for a number of successive operations, thus very greatly decreasing the operating expense and the investment in the pile construction. A

feature of the invention resides in the com bining of the shaft constructing mechanism with the means of removing the casing and also with the means of compacting the concrete in the interior of the casing. A feature of the invention also is in the type of coupling employed between the various sections of the casing, whereby splitting of the casing ends and outwardly bending of the same due to the heavy weights involved, is prevented. Another valuable feature of the invention resides in the stepped contour of the vertical section of the pile which adds in an appreciable measure to the stability of the construction. Other desirable attributes of the invention are combined in the specific type of removable and replaceable clamp 30 in the ram unit, in the ram mechanism employed including the adjustable coupling means, in the employment of a coupler in the ram unit which prevents distortion in the top of the casing, and, in general, in the novel process by which the casing is removed and the con crete inserted, step by step, accompanied, when expedient, by a tamping operation.

It is apparent that the structure of the mechanism may be modified and the various detailed steps changed in accordance with the particular requirements of the construction involved and in accordance with the specialized knowledge of the field to which the invention pertains and I do not wish therefore to limit the invention to the mechanism and process shown, except in so far as defined by the claims hereunto appended.

I desire to claim as my invention:

1. The process for pile construction which consists in sinking a shaft, lowering a plurality of superimposed co-axial casings with in said shaft, filling the inner casing with concrete approximately to the base of the next outer casing and tamping the same, subsequently removing the inner casing and filling the second outer casing with concrete approximately to a level with the base of the third outer casing and again tamping the concrete, subsequently removing the second casing, and repeating said concrete filling and casing removing until all of said casings have been removed.

2. The process for pile construction which consists in lowering a shaft to weight supporting stratum, placing a plurality of casings in said shaft, one casing extending from the top of the shaft to the base thereof, a second casing enclosing said first casing in said shaft, the base of the second casing terminating above that of the first casing, and ad ditional casings with successively higher levels positioned about said first casing within the shaft, lowering foundation material into said inner casing to the level approximating that of the second outer casing, tamping the foundation material into position while removing said inner casing, adding additional foundation material in the second casing, to the level of the base of the third casing, and subsequently removing said second casing, and subsequently alternately adding concrete and rei'noving the enclosing casing until all of said casings have been removed.

3. A process of pile construction which consists in sinking a shaft, inserting a casing in said shaft, subsequently sinking a shaft to a lower level, and lowering a second casing within said lirst casing to said lower level, subsequently sinking additionallengths of shaft and irserting additional lengths of casing until the weight supporting stratum has been reached, placing foundation supporting material in the inner casing at its base to a level approximating the base level of the second outer casing, removing said inner casing, adding additional foundation material in said second casing to a level approximating that of the base of the third outer casing, and removing said second casing, and subsequently repeating the addition of foundation material and removal of the successive casings until all of said casings have been removed and the shaft filled with concrete to the desired level.

4:. That process of building piles which. consists in spudding a vertical shaft in earth surface, lowering a plurality of casings of different dimensions into said shaft, filling said shaftwit-h foundation material and forcing said casings upwardly while simultaneously tamping said material.

5. The method of forming apile which comprises sinking a shaft in the surface of the earth; lowering a plurality of telescoping casings into the shaft; introducing foundation material into the shaft; and directing successive blows against one of said casings in an upwardly direction to raise the same; while simultaneously tamping the foundation material into the bottom of the shaft.

6. The method of forming a pile which comprises sinking a shaft into the surface of the earth; lowering a plurality of telescoping casings of different lengths into said shaft, said casings increasing in length from the larger to the smaller thereof; filling a portion of said shaft with foundation material; directing successive blows in an upwardly direction upon the longest of said casings to raise it out of the shaft; while simultaneously tainping said foundation material into the space occupied by said casing; and thereafter placing more foundation material into said shaft and raising said other casings by succcssive blows directed thereupon in an upwardly direction while simultaneously tamping said foundation material into the space occupied by said casings.

In testimony whereof. I afiix my signature.

NELSON RANDALL osBoRNE. 

